IDCI with reset lockout and independent trip

ABSTRACT

Resettable circuit interrupting devices, such as an IDCI, are provided having a reset lockout and independent trip.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to commonly owned application Ser. No.09/812,288, filed Mar. 20, 2001, entitled Circuit Interrupting Devicewith Reset Lockout and Reverse Wiring Protection and Method ofManufacture, by inventors Steven Campolo, Nicholas DiSalvo and WilliamR. Ziegler, having, which is a continuation-in-part of application Ser.No. 09/379,138 filed Aug. 20, 1999, now U.S. Pat. No. 6,246,558, whichis a continuation-in-part of application Ser. No. 09/369,759 filed Aug.6, 1999, now U.S. Pat. No. 6,282,070, which is a continuation-in-part ofapplication Ser. No. 09/138,955, filed Aug. 24, 1998, now U.S. Pat. No.6,040,967, all of which are incorporated herein in their entirety byreference.

This application is related to commonly owned application Ser. No. To BeDetermined, filed Mar. 20, 2001, entitled Reset Lockout for SlidingLatch GFCI, by inventors Frantz Germain, Stephen Stewart, DavidHerzfeld, Steven Campolo, Nicholas DiSalvo and William R. Ziegler,having which is a continuation-in-part of application Ser. No.09/688,481 filed Oct. 16, 2000, all of which are incorporated herein intheir entirety by reference.

This application is related to commonly owned application Ser. No.09/812,624, filed Mar. 20, 2001, entitled Reset Lockout Mechanism andIndependent Trip Mechanism for Center Latch Circuit Interrupting Device,by inventors Frantz Germain, Steven Stewart, Roger Bradley, David Chan,Nicholas L. DiSalvo and William R. Ziegler, having, herein incorporatedby reference.

This application is related to commonly owned application Ser. No.09/379,140 filed Aug. 20, 1999, which is a continuation-in-part ofapplication Ser. No. 09/369,759 filed Aug. 6, 1999, which is acontinuation-in-part of application Ser. No. 09/138,955, filed Aug. 24,1998, now U.S. Pat. No. 6,040,967, all of which are incorporated hereinin their entirety by reference.

BACKGROUND

1. Field

The present application is directed to resettable circuit interruptingdevices without limitation ground fault circuit interrupters (GFCI's),arc fault circuit interrupters (AFCI's), immersion detection circuitinterrupters (IDCI's), appliance leakage circuit interrupters (ALCI's),equipment leakage circuit interrupters (ELCI's), circuit breakers,contactors, latching relays and solenoid mechanisms. More particularly,certain embodiments of the present application are directed to IDCIsthat include a reset lock out portion capable of preventing the devicefrom resetting under certain circumstances and an independent tripmechanism.

2. Description of the Related Art

Many electrical appliances have an electrical cord having a line side,which is connectable to an electrical power supply, and a load side thatis connected to the appliance, which is an electrical load. Certainappliances may be susceptible to immersion in a conductive fluid, whichmay present a shock hazard. Other fault scenarios may be addressed byother circuit interrupters alone or in combination. Accordingly, theelectrical wiring device industry has witnessed an increasing call forcircuit breaking devices or systems which are designed to interruptpower to various loads, such as household appliances, consumerelectrical products and branch circuits. In particular, appliancesutilized in areas that may be wet, such as hair dryers, may be equippedwith an IDCI to protect against immersion hazards. Such products havebeen marketed by companies under brand names including Conair

SUMMARY

The present application relates to a resettable circuit interruptingdevices.

In one embodiment, the circuit interrupting device includes a userinterface. Before the device is used, it is tripped. The user must thenuse the user interface to enable a test actuator to initiate a test ofthe device. If the test passes, the device will reset. Otherwise, thedevice will be locked out. In another embodiment, the device may betripped by a user interface to a mechanical trip mechanism.

One embodiment for the circuit interrupting portion uses anelectro-mechanical circuit interrupter to cause electrical discontinuityin at least one of the phase and neutral conductive paths of the device,and sensing circuitry to sense the occurrence of a predeterminedcondition. The mechanical trip arm may be configured to facilitatemechanical breaking of electrical continuity in the phase and/or neutralconductive paths, if the trip actuator is actuated. Furthermore, themechanical trip arm or level may be configured so that it will not beoperable to reset the device.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present application are described hereinwith reference to the drawings in which similar elements are givensimilar reference characters, wherein:

FIG. 1 is a perspective view of one embodiment of as immersion detectioncircuit interrupting device IDCI according to the present application;

FIG. 2 is a schematic diagram representation of one embodiment of anIDCI according to the present application;

FIG. 2a is an exploded perspective view of components of the IDCI;

FIG. 2b is a perspective view of a reset button and trip arm of theIDCI;

FIG. 2c is a perspective view of a catch of the IDCI;

FIG. 2d is a perspective view of a latch and latch spring of the IDCI;

FIG. 3 is a top view of an IDCI according to the present application;

FIG. 4 is a partial cutaway perspective view of the IDCI along line 4shown in a tripped state;

FIG. 4a is a partial cutaway perspective view of the IDCI along line 4 ashown in a tripped state;

FIG. 4b is a partial cutaway perspective view of the IDCI along line 4 bshown in a tripped state;

FIG. 4c is a partial cutaway perspective view of the IDCI along line 4 cshown in a tripped state;

FIG. 4d is a detail view of section 4 d from FIG. 4c;

FIG. 5 is a partial cutaway front view of the IDCI in a reset lockoutstate;

FIG. 5a is a detail partial section perspective view of the IDCI alongline 5 a in a reset lockout state;

FIG. 5b is a partial cutaway perspective view of the IDCI along line 5 bshown in a reset lockout state;

FIG. 5c is a partial cutaway perspective view of the IDCI along line 5 cshown in a reset lockout state;

FIG. 6 is a partial cutaway perspective view of the IDCI shown in anintermediate state with plunger moving latch;

FIG. 6a is a detail view of the IDCI shown in an intermediate state withplunger moving latch;

FIG. 7 is a partial cutaway front view of the IDCI in an on state;

FIG. 7a is a detail partial section perspective view of the IDCI alongline 5 a in an on state;

FIG. 7b is a partial cutaway perspective view of the IDCI along line 7 bshown in an on state;

FIG. 7c is a partial cutaway perspective view of the IDCI along line 7 cshown in an on state;

FIG. 8 is a partial cutaway perspective view of the IDCI shown in anintermediate state with manual trip actuator moving latch;

DETAILED DESCRIPTION OF EMBODIMENTS

The present application contemplates various types of circuitinterrupting devices that are capable of breaking at least oneconductive path. The conductive path is typically divided between a lineside that connects to supplied electrical power and a load side thatconnects to one or more loads such as an appliance. For the purpose ofthe present application, the structure or mechanisms used in the circuitinterrupting devices, shown in the drawings and described hereinbelow,are incorporated into a IDCI device suitable for installation in anappliance or an appliance power cord. However, the mechanisms accordingto the present application can be included in any of the various devicesin the family of resettable circuit interrupting devices.

A common IDCI utilizes a single switch configured as a dual pole singlethrow (DPST) switch. In this embodiment of the present invention, S1comprises a dual pole dual throw (DPDT) center off switch. A typicalIDCI may not have a test circuit. In this embodiment, R4 is used tocreate a test circuit. A typical IDCI may have a solenoid plunger thatis not isolated from the latch. In this embodiment, latch 70 is isolatedfrom plunger 86 by insulator 74 and the plunger 86 may be shortened tomake room for the insulator. A typical IDCI may not have a test feature,as described below, this embodiment uses additional contacts and arms toprovide a line powered test of the device without power being applied tothe load.

As can be appreciated, other embodiments including those having featuresof the commonly owned applications incorporated by reference above areanticipated.

Turning now to FIG. 1, a representative IDCI 1 is shown configured withan IDCI attached at the end of an appliance power cord 2. A source ofpower may be connected to line side prongs 30, 35. The IDCI of thisembodiment has two user interfaces, a reset button 20 and independenttrip lever 40.

FIG. 2 is a schematic diagram representation of one embodiment of anIDCI according to the present application. As can be appreciated manyphysical configurations may be utilized in accordance with the teachingsof the present invention. S1 is a dual pole dual throw center off switchused for a reset with reset lockout protection using an electrical testof the device. Switch S2 and R4 comprise a test circuit that willexercise the sense circuit and coil. Coil L1 is a solenoid coil thatwill trigger a trip of the device. A sense wire is positioned to detectimmersion and connected to a sense circuit R1, R2, C1, D1 that willtrigger SCR to fire coil L1 when a fault is detected.

With reference to FIG. 2a, an exploded view of the IDCI of the presentembodiment is shown. A top cover 5 and bottom cover 6 are provided withfasteners 8. A power cord 2 having phase and neutral wires 4,3 areprovided. A strain relief 7 is provided. A printed circuit board (PCB)50 is connected to the bottom cover. A solenoid 80 having coil 82,plunger 86 and plunger bias spring 84 is connected to the PCB 50. A triplatch 70 is biased by latch spring 72 and mates with catch 60. Resetbutton 20 has a test contact 22 and is biased by spring 68. Test contact22 is connected to test wire 24 that attaches to test resistor R4 (notshown). Plugs 35, 30 have contacts 36, 31 respectively attached. Movablearms 66,62 are connected to the power cord. Arm 64 is attached tomovable arm 66 using fastener 54, 55, 56. Clamp 52 is connected to catch60. A trip arm 40 is pivotally connected in reset button 20.

With reference to FIG. 2b, reset button 20 is shown with trip arm 40 andtest contact 22.

With reference to FIG. 2c, a catch 60 is shown. The latch 70 is slidablyconnected to the catch 60 and the reset button 20 may interact with thelatch 70 inside the catch 60.

With reference to FIG. 2d, latch 70 is shown with latch spring 72 and aninsulator 74 added to insulate the plunger 86 from the latch 70.

Referring to FIG. 3, a top view of the IDCI is shown.

With reference to FIGS. 4, 4 a, 4 b, 4 c, and 4 d, the IDCI is shown ina tripped state. As shown in FIG. 4, the movable arm 66 and theconnected arm 64 are not in contact with contact 37 of prong 35 suchthat the line circuit is broken. As shown in FIG. 4b, the other movablearm 62 is also open and not connected to contact63 of prong 30. As canbe seen in FIG. 4a, the reset button 40 is in a raised state as biasedby spring 68. As shown in FIGS. 4c and 4 d, the latch 70 has movedright, releasing reset button 20 when it is moved from reset buttoncatch 26.

With reference to FIGS. 5, 5 a, 5 b, and 5 c the device is shown in areset locked out state. As shown in FIG. 5, the reset button isdepressed. As shown in FIG. 5a, test contact 22 comes in contact withlatch 70. A test circuit is closed through wire 24 and resistor R4 (notshown). As can be appreciated, if the solenoid coil 82 does not fire,the reset button will not continue as it is blocked by the latch 70.

As shown in FIG. 5c, depressing the reset button will move switch SiB toconnect the line neutral to the load neutral conductors using connector31 and arm 62. As shown in FIG. 5b, the arm 64 and its extension 64′connect to the phase prong 36 without energizing movable arm 66 that isisolated from the appliance plug phase wire 3. In this way, the IDCIcircuit may be powered without powering the appliance.

As can be appreciated, the line phase is connected to the test circuit,but not connected to the load phase during the test, as shown in FIG. 2.

As shown in FIGS. 6 and 6a, if the test circuit successfully fires thesolenoid 80, plunger 86 will strike latch 70 (at insulator 74) and willmove to the right and reset button 20 can continue downward such thatthe IDCI will enter the on state and the reset button will be latched inthe catch 60 by the latch 70 when it returns to the left under bias ofspring 72.

As shown in FIGS. 7, 7 a, 7 b, and 7 c, the IDCI is in an on state. Asshown in FIG. 7a, the reset button 20 is down in the on state and islatched by latch 70 in button groove 26. As shown in FIGS. 7 and 7b,movable arm 66 is connected to arm 64 that is connected to prong 35. Ascan be appreciated, the circuit is now complete from the line phaseprong 35 to the load phase wire 3. This differs from the situation abovewhen only the IDCI circuit was connected to the phase of the line side.As shown in FIG. 7c, the neutral side is also closed to complete theneutral circuit from the line side to the load wire 4 using contact 63of prong 30 and movable arm 62.

As shown with reference to FIG. 8 an independent trip is described. Inthis embodiment, the independent trip is a mechanical trip. Trip arm 40may be activated by a user pressing it in the X direction. The trip arm40 is pivotally connected to pivot 29 of the reset button 20. As shown,the trip lever bottom 49 will move in the Y direction, and will forcelatch 70 in the Y direction such that the reset button 40 will bereleased under bias of spring 68 and the device will be independentlytripped without the solenoid 80 firing.

As noted, although the components used during circuit interrupting anddevice reset operations are electromechanical in nature, the presentapplication also contemplates using electrical components, such as solidstate switches and supporting circuitry, as well as other types ofcomponents capable or making and breaking electrical continuity in theconductive path.

While there have been shown and described and pointed out thefundamental features of the invention, it will be understood thatvarious omissions and substitutions and changes of the form and detailsof the device described and illustrated and in its operation may be madeby those skilled in the art, without departing from the spirit of theinvention.

What is claimed:
 1. A circuit interrupting device comprising: a housingat least partially housing a circuit interrupting sensor, a circuitinterrupting sense circuit, a line conductor and a load conductor; and adouble pole double throw center off switch selectably activated by auser to power the circuit interrupting sense circuit from the lineconductor without powering the user load for testing of the circuitinterrupting sense circuit.